Method for Enhancing the Racking (Bending) Strength of Low Cost Plastic Pallets

ABSTRACT

An apparatus for enhancing the racking strength of a pallet is provided. The apparatus comprises an add-on runner for attaching to the pallet. The add-on runner comprises a rail and a first and a second support member. The rail comprises a middle attachment section, a first cantilevered end section, and a second cantilevered end section. The middle attachment section is adapted to accept a middle foot of a pallet. The first cantilevered end section includes a first end foot attachment section adapted to accept a first end foot of the pallet. The second cantilevered end section includes a second end foot attachment section adapted to accept a second end foot of the pallet. The first support member extends upwards from the first cantilevered end section towards a deck of the pallet. A second support member extends upwards from the second cantilevered end section towards the deck of the pallet.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to pallets. More specifically, exemplary embodiments provide for enhancing the racking strength of pallets.

2. Description of the Related Art

Inexpensive plastic shipping pallets do not have the strength to be stored in pallet racks. Typically, inexpensive plastic pallets are made of recycled resins, for example polyethylene. Pallet racks are metal structures for storing pallets in a vertical stack. A pallet rack consists of four (4) metal beams extending vertically from the ground. The beams are spaced slightly farther apart than the normal dimensions of a pallet. In the United States of America, pallets are generally forty-eight (48) inches by forty (40) inches. Foreign pallets are generally 1200 millimeters by 1000 millimeters. Thus, the beams of a pallet rack are arranged in a rectangular pattern, approximately forty-eight inches by forty inches.

Pallet racks have pairs of horizontal bars that are parallel and level to each other spaced evenly along the length of the vertical beams. The horizontal bars extend between the beams covering the long side of the pallet. These horizontal bars have lips extending inwards on the pallet rack. The lips extend a short distance allowing the pallets to be placed on the pair of opposing lips. Thus, the weight of the pallet is distributed from the pallet to the pallet rack through the horizontal bars.

Plastic pallets designed for racking are significantly more expensive, frequently costing twice as much or more than other plastic pallets. Current add-on runners are used to support pallets on a forklift. These add-on runners are inadequate for supporting the plastic pallets on pallet racks. Due to the design of the add-on runners and the inexpensive pallets, these pallets are not able to support much weight. If put in a pallet rack, these add-on runners deform and break due to the weight of the pallet.

BRIEF SUMMARY OF THE INVENTION

Exemplary embodiments provide an apparatus and a method for enhancing the racking strength of a pallet. The apparatus comprises an add-on runner adapted to be attached to the pallet. The add-on runner comprises a rail and a first and a second support member. The rail comprises a middle attachment section, a first cantilevered end section, and a second cantilevered end section. The middle attachment section is adapted to accept a middle foot of a pallet. The first cantilevered end section includes a first end foot attachment section adapted to accept a first end foot of the pallet. The second cantilevered end section includes a second end foot attachment section adapted to accept a second end foot of the pallet. The first support member extends upwards from the first cantilevered end section towards a deck of the pallet. Also, a second support member extends upwards from the second cantilevered end section towards the deck of the pallet.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is an oblique view of a prior art plastic pallet;

FIG. 2 is an oblique view of a prior art add-on runner for plastic pallets;

FIG. 3 is an oblique view of an add-on runner for plastic pallets in accordance with an exemplary embodiment;

FIG. 4 is an oblique view of an add-on runner for plastic pallets attached to a plastic pallet in accordance with an exemplary embodiment; and

FIG. 5 is an oblique view of an expanded corner portion of a pallet attached to an add-on runner in accordance with an exemplary embodiment.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is an oblique view of a prior art plastic pallet. Pallet 100 comprises deck 102, middle feet 104 and end feet 106. Deck 102 is the surface the material stored on the pallet is placed on. Middle feet 104 and end feet 106 extend downward from the bottom of deck 102. A pallet typically comprises three (3) middle feet 104 and six (6) end feet 106. Middle feet 104 are generally rectangular in shape and extend straight downward from deck 102. Middle feet 104 occur in the center of long side 108 of deck 102 and are evenly spaced across the length of short side 110 of deck 102.

End feet 106 are generally frusto-conical in shape and extend downward from deck 102. End feet 106 are tapered from wider at the top, at deck 102, to narrower at the bottom of the feet. Frusto-conical means having basically the shape of a cone, but the top is cut off parallel to the base. Such a shape is also known as a “frustum” or “frustrum”. End feet 106 occur at either end of long side 108 of deck 102 and are evenly spaced across the length of short side 110 of deck 102.

FIG. 2 is an oblique view of a prior art add-on runner for plastic pallets. Add-on runner 200 comprises rail 202, end sections 208, end foot attachment sections 206, and middle foot attachment section 204. Add-on runners typically are made of the same material as a pallet. The add-on runners are attachable by various means, such as, for example, but not limited to, snapping on, screwing on, bolting on, gluing on, and so forth. Add-on runners can be attached temporarily or permanently.

Middle foot attachment section 204 occurs in the middle of rail 202 and is shaped to accept the insertion of a bottom portion of a middle foot, such as middle foot 104 in FIG. 1, of a plastic pallet, such as pallet 100 in FIG. 1. End foot attachment sections 206 occur in end sections 208 and are shaped to accept the insertion of a bottom portion of a frusto-conical end foot, such as end foot 106 in FIG. 1, of a plastic pallet, such as pallet 100 in FIG. 1.

While occurring in end sections 208, end foot attachment sections 206 are spaced a distance from the end of rail 202. Thus, when add-on runner 200 is attached to a pallet, such as pallet 100 in FIG. 1, and the pallet is placed in a pallet rack, instead of the weight of the pallet being distributed to the pallet rack, the position of the end foot attachment sections causes the weight of the pallet to be distributed to the attachment points. Thus, the weight of the pallet is not supported by the pallet rack. Rather the weight is suspended between the horizontal bars of the pallet rack. This causes the end sections of add-on runner 200 to deform and break at end foot attachment sections 206.

Exemplary embodiments provide for modifying an add-on runner to increase the racking strength of a standard low cost plastic pallet. Racking strength is the amount weight or load a pallet can hold without major deformation failure when supported at the ends of the pallet. Exemplary embodiments provide two frusto-conical shaped support members that protect the cantilevered portion of the add-on runners. A cantilevered portion is that portion of a structure that projects beyond its own support. The support members transfer the weight of the pallet stored in a pallet rack from the deck of the pallet through the frusto-conical support members to the pallet rack. Because this transference of load is done with the attachable runner, the standard plastic pallet is unmodified and remains an inexpensive commodity.

FIG. 3 is an oblique view of an add-on runner for plastic pallets in accordance with an exemplary embodiment. FIG. 3 shows add-on runner 200 of FIG. 2 with support members 210 attached to rail 202 at end sections 208. Support members 210 are generally frusto-conical in shape, extending upward vertically from end section 208, tapering from a wide portion attached at end section 208 to a narrower portion at the top of support member 210.

Add-on runner 200 attaches to a pallet, such as pallet 100 in FIG. 1, at three locations on the pallet. Add-on runner attaches to pallet 100 and extends lengthwise, across the pallet at the middle of the pallet and at each end of the pallet.

Support member 210 typically is made of the same material as a pallet. However, alternate embodiments provide for support members 210 to be made from any appropriate material, such as, for example, but not limited to, wood, plastic, metal, and so forth. Support members 210 are attachable by various means, such as, for example, but not limited to, snapping on, screwing on, bolting on, gluing on, and so forth. Support members 210 may be attached temporarily or permanently.

Furthermore, support members 210 are shaped so as to fit flush against an end foot that extends from a pallet deck, such as end foot 106 of FIG. 1. In an alternate embodiment, support members 210 are shaped so as to provide a space between support member 210 and an end foot 106 of FIG. 1 that extends from a pallet deck.

FIG. 4 is an oblique view of an add-on runner for plastic pallets attached to a plastic pallet in accordance with an exemplary embodiment. FIG. 4 illustrates add-on runner 200 with support members 210 of FIG. 3 attached to pallet 100 of FIG. 1. As can be seen, pallet 100 is attached to add-on runner 200 with end foot 106 attached to end foot attachment sections 206, and middle foot 104 being attached to middle foot attachment section 204. Support members 210 extend upward from end sections 208 of add-on runner 200 to deck 102 of pallet 100. Thus, support members 210 absorb the weight from pallet 100 and distribute the weight to a pallet rack.

FIG. 5 is an oblique view of an expanded corner portion of a pallet attached to an add-on runner in accordance with an exemplary embodiment. FIG. 5 depicts a portion of pallet 512 attached to a portion of add-on rail 514. Frusto-conical end foot 506 extends downward from deck 502 towards add-on rail 514. End foot 506 is attached to add-on runner 514 at end foot attachment section 504 of end section 508. Frusto-conical support member 510 is attached to add-on runner 514 at end section 508 and extends upwards towards deck 502 of pallet 512. As can been seen, support member 510 is shaped so as to fit flush against end foot 506. Thus, support member 510 accepts the weight from pallet 512 and distributes the weight evenly over add-on runner 514, allowing the weight of the pallet to be distributed to a pallet rack system.

Thus, exemplary embodiments provide for modifying an add-on runner to increase the racking strength of a standard low cost plastic pallet, wherein the standard plastic pallet is unmodified and remains an inexpensive commodity.

The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. 

1. An apparatus for enhancing the racking strength of a pallet, the apparatus comprising: an add-on runner adapted to be attached to the pallet, the add-on runner comprising: a rail, the rail comprising: a middle attachment section adapted to accept a middle foot of the pallet; a first cantilevered end section including a first end foot attachment section adapted to accept a first end foot of the pallet; a second cantilevered end section including a second end foot attachment section adapted to accept a second end foot of the pallet; a first support member extending upwards from the first cantilevered end section towards a deck of the pallet; and a second support member extending upwards from the second cantilevered end section towards the deck of the pallet.
 2. The apparatus of claim 1, wherein the first support member and the second support member are frusto-conical in shape.
 3. The apparatus of claim 1, wherein the first support member and the second support members are integral to the first and second a second cantilevered end sections, respectively.
 4. The apparatus of claim 1, wherein the first support member and the second support member are attached to the first and second a second cantilevered end sections, respectively.
 5. The apparatus of claim 4, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by a bolt.
 6. The apparatus of claim 4, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by a screw.
 7. The apparatus of claim 4, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by snapping on.
 8. The apparatus of claim 4, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by an adhesive.
 9. The apparatus of claim 1, wherein the first support member and the second support member abut the first end foot of the pallet and the second end foot of the pallet, respectively.
 10. An apparatus for enhancing the racking strength of a pallet, the apparatus comprising: a first support member extending upwards from a first cantilevered end section of a rail towards a deck of the pallet; and a second support member extending upwards from a second cantilevered end section of the rail towards the deck of the pallet.
 11. The apparatus of claim 10, wherein the first support member and the second support member are frusto-conical in shape.
 12. The apparatus of claim 10, wherein the first support member and the second support members are integral to the first and second a second cantilevered end sections, respectively.
 13. The apparatus of claim 10, wherein the first support member and the second support member are attached to the first and second a second cantilevered end sections, respectively.
 14. The apparatus of claim 13, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by a bolt.
 15. The apparatus of claim 13, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by a screw.
 16. The apparatus of claim 13, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by snapping on.
 17. The apparatus of claim 13, wherein the first support member and the second support member are attached to the first and the second cantilevered end sections by an adhesive.
 18. The apparatus of claim 10, wherein the first support member and the second support member abut a first end foot of the pallet and a second end foot of the pallet, respectively.
 19. A method for enhancing the racking strength of a pallet, the method comprising: modifying an add-on runner to redistribute the weight of a load on the pallet to a pallet rack; attaching a plurality of the modified add-on runners to the pallet.
 20. The method of claim 19, wherein modifying the add-on runner to redistribute the weight of the load on the pallet to the pallet rack comprises: attaching a first support member extending upwards from a first cantilevered end section of the add-on runner towards a deck of the pallet; and attaching a second support member extending upwards from a second cantilevered end section of the add-on runner towards the deck of the pallet. 